GEA HGX34P Series User manual

D
GB
F
E
1
96116-01.2016-DGbFE
engineering for a better world
1
2
3
4
5
6
7
8
9
10
11
12
13
GEA Compressor HGX34P 2-pole
Assembly instructions
HGX34P/255-2 HGX34P/315-2 S
HGX34P/255-2 A HGX34P/315-2 S A HGX34P/380-2
HGX34P/315-2 HGX34P/315-2 A K HGX34P/380-2 A
HGX34P/315-2 A HGX34P/315-2 S A K HGX34P/380-2 A K

2
D
GB
F
E
96116-01.2016-DGbFE
About these instructions
Read these instructions before assembly and before using the compressor. This will avoid misunder-
standings and prevent damage. Improper assembly and use of the compressor can result in serious
or fatal injury.
Observe the safety instructions contained in these instructions.
These instructions must be passed onto the end customer along with the unit in which the compres-
sor is installed.
GEA Bock GmbH
72636 Frickenhausen
GEA Bock GmbH
Benzstraße 7
72636 Frickenhausen
Germany
Telephone [phone]
Fax [phone]
[email protected]
www.gea.com
Manufacturer
Contact

D
GB
F
E
3
96116-01.2016-DGbFE
Contents Page
1 Safety 4
1.1 Identification of safety instructions
1.2 Qualifications required of personnel
1.3 General safety instructions
1.4 Intended use
2 Product description 6
2.1 Short description
2.2 Name plate
2.3 Type key
3 Areas of application 8
3.1 Refrigerants
3.2 Oil charge
3.3 Limits of application
3.4 Limits of application K Design
4Compressor assembly 11
4.1 Storage and transport
4.2 Setting up
4.3 Maximum permissible inclination
4.4 Pipe connections
4.5 Pipes
4.6 Laying suction and pressure lines
4.7 Operating the shut-off valves
4.8 Operating mode of the lockable service connections - suction line valve
4.9 Operating mode of the lockable service connections - discharge line valve
5 Electrical connection 15
5.1 Information for contactor and motor contactor selection
5.2 Connection of the driving motor - star circuit
5.3 Connection of the driving motor - part-winding circuit
5.4 Circuit diagram
5.5 Electronic trigger MP 10
5.6 Connection of the electronic trigger MP 10
5.7
External connection MP10
5.8 Functional test of the electronic trigger unit MP 10
6 Commissioning 22
6.1 Preparations for start-up
6.2 Pressure strength test
6.3 Leak test
6.4 Evacuation
6.5 Refrigerant charge
6.6 Start-up
6.7 Avoid slugging
7 Maintenance 24
7.1 Preparation
7.2 Work to be carried out
7.3 Spare parts recommendation
7.4 Accessories
7.5 Extract from the lubricants table
7.6 Decommissioning
8 Technical data 26
9 Dimensions and connections 28
10 Declaration of installation 30
11 Service 31

4
D
GB
F
E
96116-01.2016-DGbFE
1|Safety
1.2 Qualicationsrequiredofpersonnel
DANGER Indicates a dangerous situation which, if not avoided,
will cause immediate fatal or serious injury.
WARNING Indicates a dangerous situation which, if not avoided,
may cause fatal or serious injury.
CAUTION Indicates a dangerous situation which, if not avoided,
may cause fairly severe or minor injury.
ATTENTION Indicates a situation which, if not avoided,
may cause property damage.
INFO Important information or tips on simplifying work.
WARNING Inadequatelyqualiedpersonnelposestheriskofaccidents,the
consequencebeingseriousorfatalinjury.Workoncompressors
isthereforereservedforpersonnelwhichisqualiedtoworkon
pressurized refrigerant systems:
• For example, a refrigeration technician, refrigeration mechatronic
engineer. As well as professions with comparable training, which
enables personnel to assemble,install,maintain and repair refrigeration
and air-conditioning systems. Personnel must be capable of assessing
the work to be carried out and recognising any potential dangers.
1.1 Identicationofsafetyinstructions:

D
GB
F
E
5
96116-01.2016-DGbFE
1|Safety
1.4 Intended use
1.3 Safety instructions
WARNING Risk of accidents.
Refrigerating compressors are pressurised machines and as such
call for heightened caution and care in handling.
The maximum permissible overpressure must not be exceeded,
even for testing purposes.
Risk of burns!
- Depending on the operating conditions, surface temperatures of
over 60°C on the discharge side or below 0°C on the suction side
can be reached.
- Avoid contact with refrigerant necessarily.
Contact with refrigerant can cause severe burns and skin
damage.
WARNING The compressor may not be used in potentially explosive
environments!
These assembly instructions describe the standard version of the compressor named in the title man-
ufactured by GEA. GEA refrigerating compressors are intended for installation in a machine (within
the EU according to the EU Directives 2006/42/EC Machinery Directive, 97/23/EC Pressure Equipment
Directive).
Commissioning is permissible only if the compressor has been installed in accordance with these as-
sembly instructions and the entire system into which it is integrated has been inspected and approved
in accordance with legal regulations.
The compressors are intended for use in mobile refrigeration systems in compliance with the limits
of application.
Only the refrigerant specied in these instructions may be used.
Any other use of the compressor is prohibited!

6
D
GB
F
E
96116-01.2016-DGbFE
• Semi-hermetic four-cylinder reciprocating compressor with oil pump lubrication.
• Optional in light weight aluminium design
• Suction gas cooled drive motor
2|Product description
Fig. 1
2.1 Short description
Fig. 2
Oil sight glass
Valve plate
Cylinder cover
Discharge
line valve
Oil pump
Terminal box
Suction
line valve
Drive section
Motor section
Dimension and connection values can be found in Chapter 9
Transport eyelet
Name plate
1
2
3
4
5
6
7
8
9
10
11
12
13

D
GB
F
E
7
96116-01.2016-DGbFE
2|Product description
/
HG 43 P 315-2 S AK X
2.2 Name plate (example)
2.3 Type key (example)
¹) HG - Hermetic Gas-Cooled (suction gas-cooled)
²) X
- Ester oil charge
³) Additional declaration for Pluscom compressors
4) S - More powerful motor e.g. air-conditioning applications
Version
Aluminium lightweight design
Motor variant 4)
Number of poles
Swept volume
³)
Numbers of cylinders
Size
Oil charge ²)
Series ¹)
1
2
3
4
5
13
12
7
11
6
10
8
9
19/28 SE 55
66,1
79,3
IP66
HGX34P/380-2 A
38,0
Y: 172 A
380-420V Y -3- 50HZ
440-480V Y -3- 60HZ
2900
3480
AS38125A001
Fig. 3
1 Type designation 6 Voltage, circuit, frequency
2 Machine number 7 Nominal rotation speed
3 maximum operating current 8 Displacement
4 Starting current (rotor blocked) 9 Voltage, circuit, frequency
5 ND (LP): max. permissible operating 10 Nominal rotation speed
pressure (g) Low pressure side 11 Displacement
HD (HP): max. permissible operating 12 Oil type lled at the factory
pressur e(g) High pressure side 13 Terminal box protection type
Observe the limits of application Electrical accessories can change
diagrams! the IP protection class!
50 Hz
}
60 Hz
}
GEA Bock GmbH
72636 Frickenhausen, Germany

8
D
GB
F
E
96116-01.2016-DGbFE
3|Areas of application
The compressors are factory-lled with the following oil type:
- FUCHS Reniso Triton SE 55
Compressors with ester oil charge (FUCHS Reniso Triton SE 55) are marked with an X in the type
designation (e.g. HGX34P/380-2 A).
3.1 Refrigerants
• HFKW / HFC: R134a, R407C
3.2 Oil charge
INFO For refilling, we recommend the above oil types.
Alternatives: see lubricants table, Chapter 7.5.
ATTENTION Compressor operation is possible within the operating limits
showninthediagrams.Pleasenotethesignicance
of the shaded areas. Thresholds should not be selected as design
or continuous operation points.
- Permissible ambient temperature (-20°C) - (+60°C)
- Max. permissible discharge end temperature 140°C.
- Max.permissibleswitchingfrequency8x/h.
- A minimum running time of 3 min. steady-state condition
(continuous operation) must be achieved.
For operation with capacity regulator:
- Continuous operation, when the capacity regulator is activated, is
not permissible and can cause damage to the compressor.
- The suction gas superheat temperature may need to be reduced or
set individually when operating near to the threshold.
- When the capacity regulator is activated, the gas velocity in the
systemcannotundercertaincircumstancesensurethatsufci-
ent oil is transported back to the compressor.
Foroperationwithfrequencyconverter:
- Control range of the compressor 15 - 50 Hz
(K Design 15 - 60 Hz).
- The maximum current and power consumption must not be
exceeded.Inthecaseofoperationabovethemainsfrequency,
the application limit can therefore be limited
- Use a heat protection thermostat.
- Oilreturnatlowfrequencymustbesupplied.
When operating in the vacuum range, there is a danger of air entering
on the suction side. This can cause chemical reactions, a pressure
rise in the condenser and an elevated compressed-gas temperature.
Prevent the ingress of air at all costs!
3.3 Limits of application
ATTENTION The oil level must be in the
visible part of the sight glass;
damage to the compressor is
possible if overfilled or under-
filled!
max.
min.
0,7 Ltr.
oil level
Fig. 4
~
~

D
GB
F
E
9
96116-01.2016-DGbFE
3|Areas of application
Design for other
rangesonrequest
Unrestricted
application range
Fig. 5
Fig. 6
HGX34P/315-2 (A) not suitably for R407C.
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
R134a
50 Hz
R407C
50 Hz
Unrestricted
application range
1HGX34P/380-2 (A)
observe the operating limits
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure

10
D
GB
F
E
96116-01.2016-DGbFE
3|Areas of application
3.4 Limits of application K Design (60 Hz)
• HFKW / HFC: R134a, R407C
Fig. 7
Fig. 8
R134a
60 Hz
R407C
60 Hz 1HGX34P/380-2 (A) K
observe the operating limits
Design for other
rangesonrequest
Unrestricted
application range
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Unrestricted
application range
Evaporating temperature (°C)
Condensing temperature (°C)
Suction gas temperature (°C)
Max. permissible operating
pressure (LP/HP)1): 19/28 bar
1) LP = Low pressure
HP = High pressure